Composite structure tool

Abstract

A method of producing a forming tool and a forming tool for forming an article. The forming tool includes a composite face sheet having a forming surface and an inner surface opposite the forming surface. A support structure is attached to the inner surface of the composite face sheet. The support structure includes a support shell of composite having a first surface facing the inner surface of the composite face sheet and having a second surface opposite the first surface. The support structure further includes distance members. The support shell is fixed at a distance from the composite face sheet by the distance members.

1 . A forming tool for forming an article, the forming tool comprising:
 a composite face sheet having a forming surface and an inner surface opposite the forming surface, and   a support structure being attached to the inner surface of the composite face sheet, wherein the support structure comprises a support shell of composite having a first surface facing the inner surface of the composite face sheet and having a second surface opposite the first surface, the support structure further comprises distance members, and wherein the support shell is fixed at a distance from the composite face sheet by the distance members.   
     
     
         2 . The forming tool according to  claim 1 , wherein the respective distance member has a first end attached to the inner surface of the composite face sheet and a second end attached to an edge area of a corresponding through hole in the support shell. 
     
     
         3 . The forming tool according to  claim 1 , wherein the distance members are formed of hollow circular composite tubes. 
     
     
         4 . The forming tool according to  claim 1 , wherein the support shell is arranged parallel with the composite face sheet. 
     
     
         5 . The forming tool according to  claim 1 , wherein support legs are attached to the second surface of the support shell for supporting the forming tool when placed on a floor. 
     
     
         6 . A method of producing a forming tool, the method comprising:
 providing a master tool comprising a primary surface having a contour corresponding with a composite article to be formed;   forming and curing a blank on the primary surface for producing a composite face sheet comprising a forming surface and an inner surface opposite the forming surface;   providing a support shell at a distance from the composite face sheet such that the inner surface of the latter is facing a first surface of the support shell; and   fastening distance members to the inner surface and to the support shell so that the support shell is fixed at a distance from the composite face sheet.   
     
     
         7 . The method according to  claim 6 , further comprising:
 providing through holes through the support shell for fastening the respective distance member to the support shell via an edge area of the corresponding through hole.   
     
     
         8 . The method according to  claim 6 , further comprising:
 holding the composite face sheet on the primary surface during the fastening of the distance members.   
     
     
         9 . The method according to  claim 6 , further comprising:
 forming and curing the support shell on the primary surface.   
     
     
         10 . The method according to  claim 6 , further comprising:
 fastening support legs to a second surface of the support shell being opposite the first surface of the support shell.